It’s been a long time since the last update but not because the build has halted… I’ve had my viva and got some letters (PhD), Dr Will still sounds strange! The write-up period ended up giving me a dislike of typing and computers in general so I’ve been keeping busy in the garage.

The correct sump baffle arrived quickly and is now installed. I’ve also got a new oil filter, have held off on fitting this as I may be getting a sandwich plate (between engine block and filter) to accommodate the oil pressure and temperature sensors.

Rivnut tool

I’ve made a rivnut tool for the larger size rivnuts, the tool I bought is only capable of <>

The end result used for installing M8 rivnuts:

1x M8 hex key 1x M8 cap head bolt

1x ali strip (2 mm) ~15 cm long (with suitable holes)

1x M8 nut (nyloc)

1x M8 washer

1x spanner

After a couple of practice attempts I was happy with how it worked, giving a nice even crush on the rivnut. I then installed the rivnuts for the pedal box.

Fuel system

Tank

The tank will be secured using the tank straps (made earlier) and rivnuts in the tank support brackets (also lined with foam).

Vent valve

To allow air in and out of the tank (equalise pressure) and prevent fuel escaping in the event of a roll. I’ve fitted a tank breather valve to one of the pipes from the top right of the tank (next the return pipe). This needs to be mounted vertically so I used a short length of the narrower fuel pipe, from the original bike fuel return, straight onto the vent port.

Pipe work

I’ve re-routed the return line so that it clears the mounting plate for the Quaife reverse box. All the 8 mm copper fuel lines have been secured with p-clips every 10 – 12 cm. The ends of each pipe were flared to give a good seal against the flexi lines when clamped with fuel hose clips.

Reusing R1 connector

For attaching the fuel supply fexi hose to the fuel rail I reused the original releasable joint. This just required removing the original supply line (easily trimmed off).

Sender
The sender unit needed positioning so when mounted to the top right of the tank with the float was near central, moving freely and would engage the switch before reaching the bottom of the tank (to give some reserve once warning light is on). This took a bit of thinking to get the correct bend in the float arm.

Filter

I’ve fitted a clear plastic free flowing fuel filter, so I can keep an eye on what’s going on. This is located between the tank and fuel pump.

Pump

To fit the fuel pump I’ve made a bracket from 2 mm ali strip lined with foam strip. I mounted this left of the diff with a rivnut in a chassis rail.

More photos of the fuel system install to follow, plenty of other bits have been done but thats enough computer time for now....